I have 2000 f-150 with the 4.6.When i first start it ,i can hear a slight leak from driver side manifold. it goes away after it warms up.Monro muffler wants 300.00 to change gasket not including any broken studs!!!!.What nightmare can i expect if i fix it myself? any help would be appreciated.

 

This can go either way for you. I had the same leak on my passenger side and found 2 broken studs. After getting an estimate saying somewhere between $600 and $1200, I decided to have a go at it. A couple hours and a lot of PBBlaster later I had the 6 nuts and studs that weren't broken out and 1 of the broken studs out. 2 days, 4 tanks of propane, a grinder wheel, and 1 locking pliers later that last stud was just as stuck and a lot shorter. I can't even begin to tell you how frustrating that was. I doubled up some gaskets and put in a new set of bolts, hoping 7 was going to be an improvement. All said and done I'm no further along than when I started.

All the studs that I could double up some nuts on came out for me... some easier than others, but up to that last broken stud it was a job well worth trying to do myself considering the cost. most likely I'll be taking it in and having that last one taken out for me. My advice is have at it. Work on getting all the nuts off first so you can remove the manifold. If that goes ok for you start at the studs. I'd go after the broken ones first if you have any. As long as you aren't drilling into the head any to remove them, you aren't gonna do any harm.

 

i agree with crownie. plan on taking at least a 4-5 hours for the job. pb blaster, propane torch, those sears bolt out sockets work great as well.soak everything overnite in blaster.i got lucky i didnt break any more studs taking off my 97 4.6 manifold.take your time and dont force to much. let the pb blaster and torch do the work.i learned after a few knucke slams.

 

I changed my 99' right side. Search on "exhaust stud" for methods, parts etc.

 

My slave cylinder went last Friday and I brought my truck to my mechanic, who happens to be a real good friend. They replaced the clutch, slave, etc. He told me my manifolds have at least 4 cracks in them, there are 3 or 4 snapped bolts, he didn't snap them, two missing, and the "good" ones he tried, but he just quit after 2-3 minutes trying to get them. I am not an expert, so senior members please correct me if this is wrong, but in laymans terms this is what told me. He said Ford used Steel bolts to attach the manifolds to the Aluminum cylinder heads. Well, it doesn't take long for the heat to get at them and frezee them in their. He said best case senario for me is this, either buy new manifolds and cylinder heads, have the old ones ripped off, and replaced. Or They can pull the old manifolds off with the cylinder heads and drill out the busted bolts and tap new holes. I guess this is a huge problem on these motors. My friend has a 96 Mustang GT, he has replaced all the big performance parts but has yet to put headers on it because he has 2 snapped bolts and the rest have become "one" with the motor. I have no idea what was Ford was thinking when they did that. I wish you the best of luck. Me, I am waiting until August 2008 when my inspection needs to be renewed.

 

No, you can get them out. You just weld a nut on top of the broken stud. The heat of welding helps loosen it too.

My mechanic (also a good friend) installed both new manifolds, studs/nuts, egr/manifold tube, and front o2's for $250 labor.

Look for a good local shop!

 

I will ask my buddy about doing that. Thanks for the help

 

Is it the original manifold or headers I had the same problem with Headman headers I got a small piece of plastic pipe stuck one end in my ear and tracked the leak to a crack in the header...they are a pain to work on it could take you a day and a half and a lot of bleading knuckles..id pay $300 :

 

hey spike, theres no need to replace the head. the welding on the nut works pretty well to get the busted stud out.

 

yea i've got the same problem on the truck i just bought. Since i just bought it i'm taking it back to the dealer i purchased it from tomarrow and they will be fixing it this week. Thank god because i took it to firestone to find out first what the tick noise was, and after they told me it was the exhaust manifold stud or studs being broken, they would have charged $750 for the job! Jeeze, so your price of $300 is awsome. I'll have to check my monroe for deals like that when i have problems in the future! good luck, hopefully it works out best for the both of us!

John